Flashlight



Jan. 17, 1956 e. N. BOLINGER 2,731,545

FLASHLIGHT Filed Aug. 25, 1952 INVENTUR 52 6EOE6E /V0L 50L lNGEE 4e 43 a m ATTORNEY United States Patent C) FLASHLIGHT,

George Noel Bolinger, Shelbyville, lli.

Application August ZS; 1952; Serial No. 306,099"

7-Claims. (Cl; 240-16158) Thisinvention'relates toa, flashlight, and more particularly to a. flashlight structurewhich, is extremely simple in: construction and, economical} to manufacture;

In. my copendingapplication Serial No. 297,850, filed July. 9; 1952, I have; disclosed as simplified type of flash? light construction whereintthe case of the flashlight forms, in efiect', a carton in which thebatteries are sold and which isiso simple and economical to 'manufacture that, upon the exhaustion of the batteries, it is wholly practicable to-discard the flashlight and to purchase a new one. In my copending application referred to, I-have disclosed a highly simplified form of switch device for closing a circuit through the light bulb. A similar switch device is: employedwith. the presentconstruction and forms, perse, nopart of the present invention, but is utilized in the present device ina-new andinovel manner.

An important object; ofthe; present invention is-to provide a; highly simplified; type, of flashlight construction wherein the case may beeconomically formed of; such material as cardboard. and the like, and in which the batteries are readily replaceable without discarding the flashlightas a whole.

A further object is'to provide such a flashlight wherein asimplified' type of switch device is emplcyed in combination with a. novel means for maintaining the switch device in proper position in. the case, and which single means performs at least one additional function,

A further object is to provide such a device wherein a single spring element in the flashlight case. performs three functions, namely, thethol'ding of the switch element in proper position, the establishment of electrical connection between the switch and the base of the battery remote from the bulb, and: the urging of; the batteries in a. direction toward the bulb to maintain at all times eflicient electrical: connection between thebase contact ofthe bulb and the center contact of the adjacentbattery.

A further object is to provide such a flashlight wherein all ofthe parts may be produced at a relatively low cost; wherein all of the parts are so simplified as to impartto the flashlight a high degree of ruggedness in use, and;v wherein. the parts: may be readily assembled;

Other objects and' advantages of the invention will; become apparent during the course of the following description.

In the drawing I have shown two embodiments of theinvention. In this showing:

Figure 1 is an axial sectional view through the flashlight, parts being shown in elevation and; parts being broken away;

Figure 2 is a transverse section on line 22 of Figure 1;

Figure 3 is a fragmentary perspective view of the spring device used in the flashlight, one of the batteries being shown. in dotted lines within the spring device;

Figure 4 is an enlarged fragmentary sectional view of the reflector; end of the device with the bulb and battery omitted, and showingthe reflector partially removedfrorn the case;

2 Figured is; a; detail perspective view of the. switch eleg. ment; and Figure, 6 is; a.-. fragmentary sectionalg'viem; similapto Figure l; showing-amodifiedi type; of reflector:

Refe ring o F gu e u e al 1kdesig te i he dy of; the flashlight case, which may; bemade of; a; sec of tubular material of any desiredtype, such as ca r oard; fi er, trr non o s u t ng a er a t sntefi abl hat-relative y heavy a dboar be mplay da ha interestof economy inmanufacture. It; will be: noted hat the'body lit-is. y ind l ro rend o n adi aa be cut-tothe desired; length from, any suitable tubular material, according to the number of batteries tto be used; Que-end of, the; ase permanent y; u edi cap 11, which may be made of metal, plastic, or any, other suitable material. Iihe c ap 11 is provided with a peripheral bead 12 to be rolled over or otherwisepermanently connected to the endof the body 10; and'rnay be cemented in positionif desired. I

At its opposite end', the body 16 is provided with a ferrule indicated as a whole by the numeral 1:3; and headed as, at 14 for connection with the adjacent end ot he bo y n h ame m n s i ed; I iwardly of the head 14, the ferrule 13' is provided with aninwardly projecting cylindrical portion 15 fitting within the body 10 and terminating at its inner extremity inan inturned' annular flange 16, provided with a central cir cu1a r open ing 17; f

A reflector element 18 is employed with the form of the device. shown in Figure 1 and may comprise, a flat body portion 19 and. an outwardly extending trusteconical flangeZS which increasesvvery slightly in diameter toward the associated end of'the body 1th The flange 20 is adapted to have a pressed in wedge fit in the open.- ing; 11 to be frictionally maintained in position, and the outer, extremity of the reflector. element is provided with an annular flange. 21' extending over the bead14 The reflector member will be madetpreferably, of metal and ofjthin gauge so as to possess an appreciable degree of resiliency whereby the flange 21', if necessary, may flex slightly to insure inward movement of the frusto-conical flange 2 0 to the extent necessary for thiselementto wedge tightly in the element 11 and hold the reflector element in position until it is desired to remove it.

Axially thereof, the reflector element may be provided with a suitable socket 24, shown in the present instance as being threaded to receive the base 2 5' of a light bulb 26 having a base contact 27. I

Within and substantially fitting the body 10, of the caseis a helical spring 30. This spring is of substantial length and comprises successive helical turns 31, and the end of the spring remote from the bulb 26 is bent as at 32 and then extends radially inwardly as at 33 to terini; nate in an axial projection 34 for a purpose to be described. t will be noted that the bend 32 seatsagaihst the cap 11, as shown in Figure 1, and the spring portion 33 inclines inwardly toward the axis of the case.

In the present instance the flashlight is shown as being of such size and length as to contain two conventional flashlight batteries 36 and 37, which may be arranged in the usual cardboard housings 38. Each battery has the usual metal casing 39, and center contact 49 at one end of the battery. As shown in Figure 1, the projecting end 34 of the spring bears against the base of the shell or casing 39- of the battery 37.

The switch element for the device is shown in Figures 1 and 5: and is indicated as a whole by thesnumeral; 42;,

This switch devic i fo m o a s g e fia op. of: metal offset between its ends, as at 43, to provide a finger, piece wh ch projects through Slot 44 in the casing 10, as shown in. Figure The fl ct 43. i d s e w t h ipnl ntii tg a relatively short forward shank45 and a relatively long rear shank 46, the latter of which extends between the spring-30 and the adjacent portion of the casing body lfi. The switch element normally occupies the position shown in Figure 1 with the finger piece 43 at the rear extremity of the slot 44, that is, at the end of such slot remote from the light bulb 26.

In Figure 6 of the drawing 1 have shown a slightly modified form of the invention in which those parts which are identical with the parts of the device shown in Figures 1-5 inclusive have been indicated by the same reference numerals. reflecting element is indicated by the numeral s and the rear portion of this reflecting element, indicated by the numeral 51, issubstantially parabolic; At its forward extremity, the parabolic portion of the reflector merges into a frusto-conical portion 52, similar to the portion 20 of the reflector previously described, and the reflector St) in the modified form of t e device, the

likewise is provided with an annular flange 53 overlying the head 14.

' Operation The casing body 10 is cut off to the desired length, as determined by the number of batteries to be contained in the device. It also will be aparent that, if the reflector 50 of Figure 6 is to be employed, a slightly longer casing will be necessary. The cap 11 and ferrule 13 will'be formed by any desired method and assembled upon the ends of the body 10 in any suitable or practicable manner. The spring 30 may be inserted in the device after the ferrule 13 is seated in position, but preferably is inserted prior to the placing of the ferrule 13. The spring is pushed inwardly to the position shown in Figure l and, if not pushed fully to the position in which the bend 32 viewed in Figure 1, by the spring portions 33 and 34.

Accordingly, these spring portions need notexert very great force against the battery 37, and the spring tension for this purpose is substantially less than "the friction maintaining the frusto-conical reflector portion 2t) in the opening 17. The wedging action which holds'the .re-

flecting element in position, therefore, is wholly effective against the tension of the spring portions 33 and 34 while at the same time readily permitting the removal of the.

reflector by a screw driver or similar implement inserted between the flange 21 and head 14 to remove the reflector as suggested in Figure 4.

When the batteries are exhausted, they may be replaced by inserting a suitable implement between the flange 21 and the bead 14 to loosen the reflector element from the opening 17. The reflector and bulb may be removed, the batteries dropped out, new batteries placed in position, and the reflector 13 replaced.

The form of the device shown in Figure 6 is identical with the form of the device shown in Figures 1-5, inclusive, except for the different formation of the reflector 5% where it is desired to provide a concentrated beam of light. In the modified form of the invention, the bulb is shown as having a base connection with the reflector 50 seats against the cap 11, theinsertion of the batteries 36 and 37 will accomplish this purpose. The external diameter of each battery will be slightly less than the diaceter of the opening 17 to permit the later removal and replacement of the batteries without removing the ferrule 13.

As previously stated, the switch element 42 is similar to and may be substantially identical with the switch element shown in my copending application Serial No. 297,850, filed July 9, 1952, and this switch preferably, but not necessarily, is placed in position prior to the insertion of the spring 38, and it will be apparent that the, spring engages the shank portion 46 of the switch to maintain the switch properly in position against the adjacent wall of the body 10. After the elements have been assembled, the proper bulb 26 will be screwed into position. The flashlight is now ready for operation, and the bulb may 7 be illuminated by pushing the finger piece 43 to the right,

switch element 42, ferrule 13, reflector 18, the shell of the bulb 26 and thence through contacts 27 and 40. The circuit may be broken merely by pulling back on the finger piece 43.

The circuit will be com-.

It will be apparent that the spring 30, while only a single element in itself, performs'three separate functions. The spring holds the switch element 42 against the casing 10 and frictionally resists movement thereof to hold the switch against accidental movement from any given position thereof. The spring also serves to provide electrical connection betweenthe base of the battery 37 and the switch element, and the spring por tion 33 exerts an axial force against the battery 37 to maintain electrical contact between the center contact of the battery 37 and the base of the battery 26 and to maintain the contact 40 of the battery 36 in electrical engagement with the base contact 27 of the bulb.

The spring coils 31 fit relatively snugly in the flashlight casebut fit relatively loosely around the batteries, so that the latter are readily urged toward the right, as

of the pin and slot type, which of course is conventional.

From the foregoing, it will be apparent that the flashlight as a whole may be economically formed, there being no expensive or intricate parts involved. Accordingly, the flashlight is rugged and long-lasting in construction.

i claim:

1. A flashlight comprising an insulating case, a cap structure for each end of said case, one of which car) structures comprises a reflector having means forsupporting therein a light bulb with its base contact engaging the center contact of a battery in said case, a switch element having a straight shank portion mounted in said case and having a finger piece projecting therefrom for longitudinal movement of said switch element into electrical engagement with said one cap structure, and a single spring mounted in said case and comprising a coil substantially fitting within said case said shank portion of said switch element lying between said case and said coil and contacting with said coil, said spring having a bend seated against the other cap structure and having an end projecting from said bend radially inwardly and away from such other cap structure in engagement with the end of a battery in said case to urge said center contact into engagement with the base contact of the bulb;

2. A flashlight comprising an insulating case, a .cap structure for each end of said case, one of whichcap structures comprises a reflector having means for supporting therein a light bulb with its base contact engaging the center contact of a battery in said case, a switch element mounted in said case and having a finger piece pro-. jecting therefrom for longitudinal movement of. said switch element into electrical engagement with said one cap structure, and a coil spring arranged in said case and extending from the other cap structure throughout a substantim portion of the length of said case, said'switch element having a portion lying between said case and said coil spring and having electrical contact with the latter, said spring having an integral end portion seating against said other cap structure and terminating in a substantially radially inwardly extending extremity engaging the end of an adjacent battery and flexed to transmit a longitudinal force thereto to maintain engagementlbetween said center contact and'the base of the bulb.

3. A flashlight comprising an insulating case having a cap structure at each end, one of which comprises a reflecting element having means for supporting'therein a light bulb having a base contact engagea'bie with the centercontact of a battery. arranged in said case, a switch element arranged in said case and comprising a single strip of material having an offset finger piece intermediate which said finger piece projects, one end of said switch element being movable longitudinally of said case into electrical contact with said one cap structure and the other end of said switch element lying against the inner surface of said case, and a single spring reacting between the other cap structure and the bottom of an adjacent battery to urge said center contact into engagement with the base contact of the bulb, said single spring having a coil portion substantially fitting said case, said other end of said switch element lying between said case and said coil portion to establish electrical contact with a plurality of turns of said coil portion, said switch element being slidable relative to said coil portion to maintain electrical contact therewith in any longitudinal position of said switch element.

4. A flashlight comprising an insulating case having a cap structure at each end, one of which comprises a re flecting element having means for supporting therein a light bulb having a base contact engageable with the center contact of a battery arranged in said case, a switch element arranged in said case and comprising a single strip of material having an offset finger piece intermediate its ends and said case having a longitudinal slot through which said finger piece projects, one end of said switch element being movable longitudinally of said case into electrical contact with said one cap structure and the other end of said switch element lying against the inner surface of said case, a helical spring arranged within and substantially fitting said case, said spring comprising a plurality of helical turns extending from the other cap structure throughout a substantial portion of the length of said case, said spring having a bend seating against the other cap structure and terminating in a substantially radially inwardly projecting integral end contacting with the end of an adjacent battery to exert force thereagainst longitudinally of said case to maintain said center contact in engagement with the base contact of the bulb, said other end of said switch element being seated against the inside of said case by said spring and being slidable over the latter longitudinally of said case.

5. A flashlight comprising an insulating case, a cap closing one end of said case, a ferrule fixed to the other end of said case and having an inturned flange forming an annular opening, a reflecting element having a slightly tapered annular portion movable into wedging engagement with said flange to be frictionally maintained in position therein, said reflecting element having an axial opening to receive and support a light bulb having a base contact engageable with the center contact of a battery in said case, a longitudinally slidable switch element within said case having a portion projecting therethrough and manually movable to move said switch element longitudinally of said case, said ferrule and said reflector constituting a cap structure and one end of said switch element being electrically engageable with such cap structure upon longitudinal movement of said switch element in one direction, and means for establishing electrical connection between the other end of said switch element and the end of a battery adjacent said cap, said means comprising a resilient element reacting between said cap and the end of an adjacent battery to maintain electrical engagement between said center contact and the base contact of said bulb, the force of said spring element being less than the frictional resistance to movement of said reflecting element out of said flange.

6. A flashlight comprising an insulating case, a cap closing one end of said case, a ferrule fixed to the other end of said case and having an inturned flange forming an annular opening, a reflecting element having a slightly tapered annular portion movable into wedging engagement with said flange to be frictionally maintained in position therein, said reflecting element having an axial opening to receive and support a light bulb having a base contact engageable with the center contact of a battery in said case, a longitudinally slidable switch element within said case having a portion projecting there through and manually movable to move said switch element longitudinally of said case, said ferrule and said reflector constituting a cap structure and one end of said switch element being electrically engageable with such cap structure upon longitudinal movement of said switch element in one direction, and means for establishing electrical connection between said other end of said switch element and the end of the battery adjacent said cap, comprising a helical spring having a plurality of turns extending throughout a substantial portion of the length of said case, said turns of said spring maintaining said other end of said switch element in engagement with said case and being in electrical contact with said other end of said switch element and frictionally resisting longitudinal movement thereof to maintain said switch element in any adjusted position.

7. A flashlight constructed in accordance with claim 6 wherein said helical spring is provided with a bend seating against said cap and terminating in a substantially radial inner extremity engaging the adjacent end of a battery to maintain said center contact in engagement with the base contact of the bulb.

References Cited in the file of this patent UNITED STATES PATENTS 1,758,835 Hime May 13, 1930 2,222,303 Shough Nov. 19, 1940 FOREIGN PATENTS 440,960 Great Britain Jan. 6, 1936 

